Cross-linked polymers from vinyl benzene sulfonate salts, ethylenic hydroxy monomers and hydroxyl containing binder polymers

ABSTRACT

Cross-linked conductive polymer, coating compositions and light sensitive elements containing at least one antistat layer where the cross-linked polymer is a copolymer of a vinylbenzene sufonic acid and an ethylenically unsaturated monomer containing at least one primary hydroxl group cross-linked with a methoxyalkylmelamine.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a division of U.S. application Ser. No. 07/527,414,filed May 23, 1990 now U.S. Pat. No. 5,096,975.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to cross-linked conductive polymers and moreparticularly to antistat layers employing the cross-linked conductivepolymers. Additionally, the invention relates to light sensitiveelements having at least one antistat layer.

2. Description of Related Art

Schadt, U.S. Pat. No. 4,225,665, discloses an antistatic composition forphotographic films wherein a conductive polymer having carboxyl groupsand a hydrophobic polymer containing carboxyl groups are cross-linkedwith a polyfunctional aziridine.

Hardam et al, U.S. Pat. No. 4,668,748, discloses a cross-linkableconductive copolymer of a monomer of sodium styrene sulfonate type and avinyl amine monomer.

Because of the electrostatic charges that build up on polymeric articlesas they move in contact with other surfaces of high dielectric constant,it has been necessary to provide a conductive layer on polymericarticles in order to prevent the build up of charges. This problem isparticularly acute in photographic applications, both during thepreparation thereof and during use and development, because during thepreparation it is undesirable to have static discharge that will exposelocalized areas of the light sensitive recording media. Subsequently,both during the exposure cycle and the development cycle, static chargesare unwanted because they attract dirt and dust particles which appearas imperfections in the final presentation of the developed image,whether it be in the form of a print or projected image. The two patentsmentioned above, provide antistatic properties during the preparationand subsequently during processing of the film and are for that reasondefined as having permanent antistat properties.

It is also desirable to provide antistat coatings for light sensitiveelements wherein the antistat layers also serve as subbing layers forsubsequently applied layers in the recording element, overcoat layer andthe like. When employed as subbing layers, in addition to havingantistat properties, the layers should also promote adhesion. Whenserving as an overcoat, the layer should also provide the recordingelement a measure of protection with regard to abrasion. Abrasion is anever present problem in photographic films, particularly because in allstages of its preparation, use and development, the film encountersother objects such as rollers and the like. Indeed in motion picturefilm, for example, the film is constantly moved passed a variety ofelements in the projection apparatus which can cause imperfections as aresult of contact therewith. Further, as the film is utilized inprojection apparatus, it attracts dust particles from the environmentwhich when projected become enlarged. It is desirable to remove suchparticles and therefore it is necessary that the film have a measure ofabrasion resistance in order to withstand brushing or the like toaccomplish this purpose.

It is therefore desirable to provide an antistat layer in a photographicelement that not only is of the proper conductivity to prevent the buildup of electrostatic charges but also one which also enhances itsfunction as a subbing layer to promote adhesion or as an overcoat towithstand the various forces applied to the surface of the particularphotographic element.

SUMMARY OF THE INVENTION

The invention is directed to cross-linked conductive polymers to coatingcompositions thereof and to light sensitive elements containing at leastone antistat layer of a copolymer of (1) an ammonium or alkali metalsalt of a vinyl benzene sulfonic acid and (2) an ethylenicallyunsaturated monomer containing at least one primary hydroxyl groupcross-linked with a methoxyalkylmelamine. The invention alsocontemplates coatings of such cross-linked polymers particularlycoatings employed as antistatic layers in light-sensitive recordingelements such as photographic films wherein the coatings are utilized asovercoats, subbing and backing layers to reduce fog caused by staticdischarges during manufacturing, customer use and the like.

DETAILED DESCRIPTION OF THE INVENTION

The invention thus contemplates conductive cross-linked polymerscontaining a water soluble electrically conductive addition polymerhaving functionally attached hydroxyl groups and being a copolymer of analkali metal or ammonium salt of a vinyl benzene sulfonic acid and anethylenically unsaturated monomer containing at least one primaryhydroxyl group where this conductive polymer is cross-linked by reactionwith a multi-functional methoxyalkylmelamine. By "multifunctional" ismeant a methoxyalkylmelamine having at least two methoxy groups andpreferably those having 3 or more methoxy groups.Hexamethoxyalkylmelamines are most preferred. Optionally, andpreferably, the invention contemplates cross-linked polymers wherein inaddition to the conductive addition polymer and the melaminecross-linking agent, the composition includes a hydroxyl containinglatex binder polymer which provides resiliency to the antistat layers.

Thus, the invention contemplates not only the cross-linked polymersprepared utilizing the components indicated above, but also contemplatesaqueous solutions or dispersions of the conductive addition polymer, anhydroxyl containing binder polymer which is water soluble or waterdispersible and a methoxyalkylmelamine cross-linking agent.

In the preparation of the water soluble electrically conductive additionpolymers having functionally attached hydroxyl groups, any suitableammonium or alkali metal salt of a vinyl benzene sulfonic acid may beused such as, for example, sodium styrene sulfonate, ammonium styrenesulfonate, potassium styrene sulfonate, lithium styrene sulfonate, vinylmonoalkyl substituted benzene sulfonates, such as, for example, theammonium, sodium, potassium or lithium salts of the following: vinyltoluene sulfonic acid, vinyl ethylbenzene sulfonic acid, vinyln-propylbenzene sulfonic acid, vinyl isopropylbenzene sulfonic acid,vinyl n-butyl benzene sulfonic acid, vinyl tert-butyl benzene sulfonicacid, vinyl isobutyl benzene sulfonic acid, vinyl isopentyl benzenesulfonic acid, vinyl 3-methylbutyl benzene sulfonic acid, vinyl n-hexylbenzene sulfonic acid, vinyl isohexyl benzene sulfonic acid and thelike. It is preferred that the alkyl group of the substitutedvinylbenzene sulfonate have from 1-6 carbon atoms.

In the preparation of the water soluble electrically conductive polymer,any suitable compound containing an ethylenically unsaturated doublebond capable of forming an addition polymer with the vinyl benzenesulfonate compound and containing at least one primary hydroxyl groupmay be employed such as for example, hydroxy ethylmethacrylate, hydroxyethylacrylate, hydroxy n-propylmethacrylate, hydroxy n-butylacrylate,hydroxy containing acrylamides such as, N-methylol acrylamide, N-ethanolacrylamide dihydroxyethylmaleate, vinylbenzyl alcohol and the like. Thebenzene sulfonate and the ethylenically unsaturated hydroxyl containingcompound are employed in ratios varying from 95:5 to 15:85. Preferablythe hydroxyl containing compound should be present in at least 25 molepercent and most preferably from about 25 to about 50 mole percent. Itis necessary that sufficient hydroxyl groups be present on the additionpolymer in order to achieve the desired level of cross-linking whenreacted with the methoxyalkylmelamine. Thus, when ethylenicallyunsaturated compounds containing more than a single hydroxyl group areemployed, the molar amount of ethylenically unsaturated compoundcontaining hydroxyl groups may be lowered. Further, it is also necessarythat this copolymer contain sufficient sulfonate groups to provide thecross-linked polymer with sufficient conductivity for the specificapplication for which the conductive polymer is to be used. Thus, it maybe necessary to modify the quantities of the two ingredients of thecopolymer to achieve the proper balance of cross-link sites and saltgroups.

When a binder polymer is to be employed in the preparation of theconductive polymers in accordance with this invention, any suitablehydroxyl containing solution or latex polymer may be employed such asfor example, polyvinyl alcohol, polyhydroxy ethylacrylate,polyhydroxyethylmethacrylate, polyhydroxypropylacrylate or methacrylate,polyhydroxyethylcellulose, polyhydroxylpropylcellulose, N-methylolacrylamide gelatin, polyhydroxyl ethyl acrylamide, water solublecellulose acetate and the like. The presence of a hydroxyl containingbinder polymer is preferred as the antistat layers are less brittle. Itis further preferred that the binder polymer be employed in an amount offrom about 20 to about 50 percent by weight of the coating compositionto achieve abrasion resistance and permanancy of the antistaticproperties.

As cross-linking agents, any suitable methoxyalkylmelamine may beemployed such as for example, those multifunctionalmethoxyalkylmelamines having at least 2 and preferably 3 to 6methoxyalkyl groups, such as hexamethoxymethylmelamine,trimethoxymethylmelamine, hexamethoxyethylmelamine,tetramethoxyethylmelamine, hexamethoxypropylmelamine,pentamethoxypropylmelamine, trimethoxybutylmelamine and the like. Thecross-linking agent should be employed in an amount of from about 20percent to about 75 percent by weight depending upon the degree ofcross-linking desired in the final coated layer. The cross-linking agentis preferably used in an amount of from about 25 to about 50 percent byweight. It is preferred that hexamethoxymethylmelamine be employed.

In the preparation of coating compositions for application to any typeof support to which antistatic properties are to be imparted, theconductive polymer, the cross-linking agent and the binder polymer, ifone is to be employed, is dissolved or suspended in an aqueous medium.Surfactants may also be added to facilitate solution or dispersion or asa coating aid. Suitable surfactants include sodium lauryl sulfonate,dioctyl sodium sulfosuccinate, sodium octylphenylpolyether sulfonate,saponin and the like.

The coating compositions, in accordance with the above, may be appliedin any suitable location with respect to the type of photographic filmdesired. The antistatic coatings in accordance with this invention aresuitable for all types of light sensitive recording elements includingcommercial photographic film, graphic arts films, x-ray films,microfilm, electrophotographic elements and the like. Any suitablephotographic support may be employed such as for example,polyethyleneterephthalate; cellulose esters including cellulosediacetate, cellulose triacetate, paper, resin coated paper,polycarbonate and the like. The coating compositions may be applieddirectly to one surface of the support or it may be applied to thesurface of any other layer of the photographic element. It may bedesirable prior to applying the coating the composition to subject theunderlying surface to corona discharge treatment in accordance withtechniques known in the art. The antistatic layer may be applied eitherabove or beneath a photosensitive layer such as a gelatin layercontaining silver halide or the like. Subbing layers suitable forpromoting adhesion of the various layers may be employed in accordancewith the common knowledge known in the art especially that taught inU.S. Pat. Nos. 2,678,235; 2,627,088; 2,703,290; 2,794,742; 2,852,378 and2,943,937.

The compositions in accordance with this invention may be applied in anysuitable coverage based on the dry weight of the composition andpreferably in a coverage of from about 5 to about 200 milligrams persquare foot depending upon the type of layer being applied. For asubbing layer the coverage preferably should be about 5 to 50 milligramsper square foot; for a backing layer from about 25 to about 200milligrams per square foot. Subsequent to application in the givenlocation with respect to the structure of the light sensitive recordingelement, the antistat layer is subjected to drying and curing whichtransforms the aqueous coating composition into a permanent antistatlayer which is a highly abrasion resistant, water resistant transparentlayer. In the curing of the antistat layer, temperatures of from about25° C. to about 200° C. may be employed. Preferably a temperature fromabout 80° C. to 140° for approximately 3 to 10 minutes are employed.

The conductive cross-linked polymer coatings in accordance with thisinvention provide extremely good protection against the occurrence ofelectrostatic charges on the film in addition to providing abrasionresistant coatings: thereby serving the dual purpose of an antistatcoating and a protective overcoat.

The invention will be further illustrated by the following examples:

EXAMPLE 1--PREPARATION OF CONDUCTIVE POLYMER

A solution of 10 grams of sodium styrene sulfonate, 10 grams ofhydroxyethylmethacrylate and 0.1 gram sodium persulfate and 180 grams ofdistilled water is placed in a flask equipped with a condenser. Thesolution is sparged with nitrogen for 30 minutes and then heated in anoil bath maintained at 90° C. for 20 hours. The solution is cooled toroom temperature to yield approximately 99% conversion to a copolymerwith a molar ratio of 4:6 sodium styrene sulfonate tohydroxyethylmethacrylate.

EXAMPLE 2--PREPARATION OF COATINGS

The composition prepared in Example 1 is diluted to a 2% solids solutionin water. Seventy grams of this solution are mixed with 30 grams of a 2%solids solution in water of a terpolymer of n-butylacrylate/acrylicacid/hydroxyethylmethacrylate (70/10/15), 20 grams of a 2% by weightsolution in ethanol of hexamethoxymethylmelamine and 1 gram of a 10% byweight aqueous solution of a surfactant sold under the trade designationOlin 10G. This formulation is coated with a doctor blade onto apolyethylene terephthalate film base previously coated with an adhesionpromoting coating of poly(acrylonitrilevinylidene chloride-acrylic acid)latex. The sample is dried for 5 minutes at 100° C. to give anantistatic layer with a dry weight of 50 milligrams per square foot.This antistat coating exhibits a surface resistivity, measured as logohm/per sq, at 30% relative humidity after immersion in 95° F. water for0 minutes, 0.5 minutes, 1 minute, 3 minutes and 5 minutes as 9.1, 9.1,9.2, 9.1 and 9.1, respectively.

EXAMPLE 3

The procedure of Example 2 is repeated. The antistat layer thus appliedis overcoated with a bis(vinyl sulfonyl methane)-hardened gelatin layerapplied in a coverage of 200 milligrams per square foot. This sample istested for adhesion of the gelatin layer and for permanence of theantistatic properties after treatment in typical film developer andfixer. Dry adhesion is checked by scribing 1/8 inch by 1/8 inch squarehatch marks in the coating with a razor blade, placing a piece of hightack tape over the scribed area and then quickly pulling the tape fromthe surface. The amount of area removed is the measure of dry adhesion.No discernible area is removed.

Wet adhesion is tested by placing the sample in developer and fixer at95° F. for 30 seconds each and then rinsing the sample in distilledwater. While still wet, a one millimeter wide line is scribed in thegelatin layer and finger rubbed vigorously across the scribe line. Noincrease in line width is observed thereby showing excellent adhesion toa gelatin layer.

A second sample prepared as above is also treated for 30 seconds each indeveloper and fixer maintained at 95° F., rinsed in distilled water, airdried and equilibrated at 20% RH. The internal resistivity is measuredas 12.5 log ohm per square.

It should be understood that any of the hydroxyl containing binderpolymers enumerated above, any of the methoxyalkylmelamines and anyconductive polymer as indicated may be employed throughout the workingexamples set forth above in like quantities to achieve comparableresults without departing from the spirit of this invention.

What is claimed is:
 1. A conductive cross-linked polymer comprising fromabout 20 to about 50 percent by weight of an hydroxyl containing binderpolymer, the reaction product of a water-soluble electrically conductivepolymer having functionally attached hydroxyl groups and being anaddition product of (1) an ammonium or alkali metal salt of avinylbenzene sulfonic acid and (2) an ethylenically unsaturated monomercontaining at least one primary hydroxyl group and amethoxyalkylmelamine. r
 2. The conductive cross-linked polymer of claim1 wherein the methoxyalkylmelamine is present in an amount of from about20 to about 75 percent by weight.
 3. The conductive cross-linked polymerof claim 1 wherein the methoxyalkylmelamine is present in an amount offrom about 25 to about 50 percent by weight.
 4. The conductive polymerof claim 1 wherein the hydroxyl containing binder polymer is watersoluble.
 5. The conductive polymer of claim 1 wherein the hydroxylcontaining binder polymer is water dispersible.
 6. A coating compositionfor applying an electrically conducting layer to a surface of a lightsensitive element which comprises from about 20 to about 50 percent byweight of a water soluble or water dispersible hydroxyl containingbinder polymer, a water soluble electrically conductive polymer havingfunctionally attached hydroxyl groups and being an addition product of(1) an ammonium or alkali metal salt of a vinylbenzene sulfonic acid and(2) an ethylenically unsaturated monomer containing at least one primaryhydroxyl group and a methoxylakylmelamine.
 7. The coating composition ofclaim 6 wherein the methoxyalkylmelamine is present in an amount of fromabout 20 to about 75 percent by weight.
 8. The coating composition ofclaim 6 wherein the methoxyalkylmelamine is present in an amount of fromabout 25 to about 50 percent by weight.
 9. The coating composition ofclaim 6 wherein the hydroxyl containing binder polymer is water soluble.10. The coating composition of claim 6 wherein the hydroxyl containingbinder polymer is water dispersible.
 11. The coating composition ofclaim 6 wherein the methoxyalylmelamine has from 3 to 6 methoxy groups.12. The coating composition of claim 6 wherein the methoxyalkylmelaminein an hexamethoxyalkylmelamine. m